Multiple stage deformation reinforcement structure for impact absorption

ABSTRACT

A structural reinforcement for a vehicle comprising: a) a carrier having a base wall from which a plurality of projections extend, the plurality of projections including at least one first projection and at least one second projection and the at least one first projection having a height greater than a height of the at least one second projection; b) an activatable material which is heat activatable and affixed to the carrier, configured to secure the carrier in a cavity of the vehicle; wherein in event of an impact, the at least one first projection and second projection are configured to deform toward the base wall and/or in a direction of an impact load in response to the impact load; and the at least one first projection is configured to receive the impact load and deform before the at least one second projection receives the impact load and deforms.

FIELD

The present disclosure relates generally to structural reinforcement,sealing, and/or baffling of an article, and more particularly to astructural reinforcement of an automotive vehicle which is configured toabsorb and distribute an impact load in a multi-stage deformation uponimpact.

BACKGROUND

In the automotive industry, there is an ongoing need for improvingvehicle performance in the event of collisions or other impacts whilemaintaining or improving competing requirements, such as vehicle weightand fuel efficiency. One particular aspect that has been addressed iscrash impact to front, rear, and/or side body panels and pillars, andpreventing deformation of automotive body panels and pillars into thepassenger compartment. While standard heavier metal reinforcementsprovide effective structural reinforcement, they result in heaviervehicles with reduced fuel efficiency. Thus, there is a need forstructural reinforcements in vehicles which allow vehicles to meet crashimpact requirements and continuously increasing and stricter fuelefficiency requirements.

In an ongoing effort to reduce weight and provide enhanced structuralreinforcement of vehicles during crash impact, it would be attractive tohave the impact load distributed in a way to cause absorption anddistribution of the impact load. It would be attractive to have theimpact load distributed in a way to cause a progressive collapse of astructural reinforcement, body panel, and/or pillar in a controlledmanner.

SUMMARY

The present disclosure relates to a structural reinforcement for avehicle comprising: a) a carrier having a base wall and a plurality ofprojections extending from the base wall, the plurality of projectionsincluding at least one first projection and at least one secondprojection and the at least one first projection having a height greaterthan a height of the at least one second projection; b) an activatablematerial which is heat activatable and affixed to the carrier, whereinthe adhesive material is configured to secure the carrier in a cavity ofthe vehicle; wherein in event of an impact, the at least one firstprojection and the at least one second projection are configured todeform toward the base wall and/or in a direction of an impact load inresponse to the impact load; and the at least one first projection isconfigured to receive the impact load and deform before the at least onesecond projection receives the impact load and deforms.

The structural reinforcement of the disclosure may include one or moreof the following features in any combination: the carrier may include afirst portion and a second portion separated by the base wall; the atleast one first projection and at least one second projection may bepart of the first portion; the second portion may include at least onefirst projection extending from the base wall in an opposite directionas the plurality of projections of the first portion; the carrier may bea molded polymeric carrier; the molded polymeric carrier may include atleast one insert made of a different material than the molded polymericcarrier; the material of the insert may have a higher yield strengththan a yield strength of the molded polymeric carrier; yield strengthsmay be measured according to ASTM D695 and/or ASTM D790; the carrier maybe a single molded one-piece structure; at least a portion of thecarrier may include localized fiber reinforcement; the localized fiberreinforcement may be woven, nonwoven, or both; the activatable materialmay be activated by heat in an automotive vehicle painting operation(i.e., paint bake oven); the activatable material may be a structuralfoam, an acoustical foam, a sealant, or a combination thereof; theactivatable material may expand upon activation; the activatablematerial may be based upon a polyolefin, an epoxy, or any combinationthereof; the activatable material may be a thermoplastic and/orthermoset; a material of at least a portion of the carrier and/or thebase wall may be a polyamide, a polysulfone, or both; at least one firstprojection may be part of a first set of a plurality of projectionshaving a similar height; at least one second projection may be part of asecond set of a plurality of projections having a similar height; theheight of the at least one first projection and/or at least one secondprojection may be a distance from the base wall to an opposing end ofthe first projection; a first set of the plurality of projections and asecond set of the plurality of projections may alternate relative toeach other on the base wall (i.e., a first projection followed by asecond projection followed by a second projection); a plurality ofprojections may include a pair of sidewalls opposing and distanced fromone another; the plurality of projections may include a pair of endwalls opposing and distanced from one another; a pair of end walls maybe adjoining a pair of side walls to define a peripheral wall structurewhich may be generally continuous; the carrier may include at least onebridging wall which may bridge a pair of side walls, a pair of endwalls, or both; he plurality of projections may include the at least onebridging wall; at least one of the first set of projections, at leastone of the second set of projections, or both may form at least one ofthe bridging walls; the pair of side walls, a pair of end walls, atleast one bridging wall may have a same height or differing height asone another; at least one of the bridging walls may have a height whichis less than the height of the pair of side walls, the pair of endwalls, or both; the plurality of projections may include at least onepair of intersecting projections; at least one first projection mayintersect with at least one second projection; at least one of the firstset of projections may intersect at least one of the second set ofprojections; at least one of the first set of projections may intersectat least one of the second set of projections; each individualprojection of the at least one pair of intersecting projections may havedifferent heights or same heights than each other; some of the pluralityof projections may form one or more cell-like structures extending fromthe base wall having two or more walls, three or more walls, four ormore walls, five or more walls, or any combination thereof; theplurality of projections may include one or more ribs, posts, tabs,extensions, the like, or any combination thereof; the second set ofprojections may be recessed compared to the first set of projections;the second set of projections may be generally parallel to one another;the second set of projections may be generally at an angle to at leastsome of the first set of projections, may be generally parallel to atleast some of the first set of projections, or both; the deformation ofthe at least one first projection and/or the at least one secondprojection in response to the impact load may be plastic deformation;the impact load may be a force resulting from a vehicle crash orcollision; the impact load may result from either side, front, or rearimpact to the vehicle; at least one first projection may have a samethickness as the at least one second projection; the first set ofprojections may have the same thickness as the second set ofprojections; the deformation of the first projection and/or the secondprojection may include a buckling of the first projection and/or thesecond projection; the carrier may include a first portion adapted foroutward placement in a first cavity of the vehicle; the first cavity maybe proximate an outer panel of the vehicle; the carrier may include asecond portion adapted for inward placement in a first cavity of theautomotive vehicle, in a second cavity of the vehicle which adjoins thefirst cavity and is positioned inwardly in the vehicle, or both; a firstcavity of the vehicle and a second cavity of the vehicle may beseparated by a wall; the wall may include an opening into which thecarrier is partially inserted; the opening may have an overall sectionalarea that is occupied by less than 80% by the carrier; and theactivatable material may be heat activated.

The present disclosure relates to a method for absorbing energy in theevent of an impact to a vehicle, the method comprising the steps ofcollapsing a carrier in a staged collapse in response to an impact load.

The method for absorbing energy may include one or more of the followingfeatures in any combination: collapsing the carrier may include a firstportion of the carrier before a second portion of the carrier; at leastone first projection may plastically deform before at least one secondprojection in response to the impact load; and at least one secondprojection may receive a portion of the impact load after the at leastone first projection is deformed to a certain height or otherpre-determined condition.

The present disclosure relates to a method for making a structuralreinforcement, comprising: a) performing finite element analysis tosimulate the impact load; b) generating a design of the carrier basedupon the results of the finite element analysis; c) injection moldingthe carrier according to the design; and d) locating the activatablematerial onto an external surface of the carrier.

The present disclosure further relates to a method of installing astructural reinforcement into a cavity, comprising: a) disposing thestructural reinforcement into the cavity or affixing the structuralreinforcement to a wall of a cavity; and b) activating the activatablematerial so that the activatable material adheres to a surface of thecavity.

The structural reinforcement provides a carrier with a plurality ofprojections which cooperate with one another to absorb and distribute animpact load. The plurality of projections allow the carrier to have amulti-stage deformation and thus allow a progressive collapse of thestructure reinforcement.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a structural reinforcement according to theteachings.

FIG. 2 illustrates a first portion of a carrier of a structuralreinforcement according to the teachings.

FIG. 3 illustrates a second portion of a carrier of a structuralreinforcement according to the teachings.

FIG. 4a illustrates a plan view of a first portion of a carrieraccording to the teachings.

FIG. 4b illustrates a plan view of a first portion of a carrieraccording to the teachings.

FIG. 5a illustrates a cross-section view of a carrier according to theteachings.

FIG. 5b illustrates a cross-section view of a carrier according to theteachings.

FIG. 6a illustrates a cross-section view of a carrier according to theteachings.

FIG. 6b illustrates a cross-section view of a carrier according to theteachings.

FIG. 6c illustrates a cross-section view of a carrier according to theteachings.

FIG. 6d illustrates a cross-section view of a carrier according to theteachings.

FIG. 7 illustrates a structural reinforcement according to theteachings.

FIG. 8 illustrates an impact load deforming a first portion of a carrieraccording to the teachings.

FIG. 9 illustrates an impact load deforming a first and second portionof a carrier according to the teachings.

FIG. 10 illustrates a carrier receiving an impact load directed toward abase wall according to the teachings.

FIG. 11 illustrates a first plurality of projections of a first portionof a carrier deforming from the impact load according to the teachings.

FIG. 12 illustrates a first and second plurality of projections of afirst portion of a carrier deforming from an impact load according tothe teachings.

FIG. 13 illustrates an impact load transferring from the first portionto the second portion of a carrier and deforming a plurality ofprojections of the second portion according to the teachings.

FIG. 14 illustrates a plan view of a structural reinforcement accordingto the teachings.

FIG. 15 illustrates a perspective view of a structural reinforcementassembled to a panel according to the teachings.

FIG. 16 illustrates a plan view of a structural reinforcement assembledto a panel according to the teachings.

DETAILED DESCRIPTION

The present teachings meet one or more of the above needs by theimproved devices and methods described herein. The explanations andillustrations presented herein are intended to acquaint others skilledin the art with the teachings, its principles, and its practicalapplication. Those skilled in the art may adapt and apply the teachingsin its numerous forms, as may be best suited to the requirements of aparticular use. Accordingly, the specific embodiments of the presentteachings as set forth are not intended as being exhaustive or limitingof the teachings. The scope of the teachings should, therefore, bedetermined not with reference to the above description, but shouldinstead be determined with reference to the appended claims, along withthe full scope of equivalents to which such claims are entitled. Thedisclosures of all articles and references, including patentapplications and publications, are incorporated by reference for allpurposes. Other combinations are also possible as will be gleaned fromthe following claims, which are also hereby incorporated by referenceinto this written description.

The disclosure relates to a structural reinforcement. The structuralreinforcement includes a carrier. The carrier includes a base wall and aplurality of projections extending from the base wall. The plurality ofprojections may include at least one first projection and at least onesecond projection. The plurality of projections may extend at differentheights from the base wall, thereby defining a plurality of deformingstages. The structural reinforcement includes an activatable materialwhich may be configured to secure the carrier in a cavity of thevehicle. The structural reinforcement may find particular use inabsorbing and/or distributing an impact load in the event of an impact,such as a crash or collision. In the event of an impact and in responseto an impact load, the at least one first projection and the at leastone second projection are configured to deform toward the base walland/or in a direction of the impact load. The at least one firstprojection is configured to receive the impact load and deform beforethe at least one second projection receives the impact load and deforms.By having at least one projection deform prior to having at least onesecond projection deform, the energy of the impact load is able to beabsorbed in stages and distributed, thus reducing the impact loadtransferred from an outside of the vehicle to an interior of thevehicle.

The reinforcement structure may specifically be adapted to providesealing, baffling or reinforcement within a cavity of a vehicle. It iscontemplated that the reinforcement structure may be applied (e.g.,assembled) to various articles of manufacture such as boats, trains,buildings, homes, furniture, or the like. It has been found however,that the reinforcement structure is particularly suitable forapplication to automotive vehicles. The term “vehicle” may be used todescribe any transportation vehicle, including a boat, train, automotivevehicle, plane, motorcycle, and the like.

The reinforcement structure may find particular use in absorbing impactassociated with an impact load. An impact load may be understood as aforce generated by impact to a surface of a vehicle, such as during acollision. The impact load may be a side impact (passenger or driverside), a rear impact, or front impact. The reinforcement structure maybe useful in reinforcing a cavity in a body panel, body pillar, or crashbeam. For example, the reinforcement structure may be disposed within acavity of a B-pillar, door panel, quarter panel, dash panel, the like,or any combination thereof. The reinforcement structure may absorb anddistribute impact such that at least a portion of the impact load is nottransferred into the passenger compartment.

The structural reinforcement includes a carrier. The carrier mayfunction to affix the structural reinforcement to a surface, absorband/or distribute energy from an impact load; provide a surface ofactivatable material, include a plurality of projections, or anycombination thereof. The carrier may have any size, shape, and/orconfiguration to affix the structural reinforcement to a surface, absorband/or distribute energy from an impact load; provide a surface ofactivatable material, include a plurality of projections, or anycombination thereof. Features part of the carrier, such as a base wall,one or more projections, or both may be integrally molded or formed froma single material. The carrier may be a one-piece structure or may becomprised of multiple pieces. The carrier may include an activatablematerial which may be located only onto select portions of the carrier.The carrier may include one or more portions adjacent to one another.The carrier may include a plurality of projections. The carrier mayinclude one or more cell-like structures. The carrier may include one ormore walls. The one or more walls may be formed by some or all of theplurality of projections. The carrier may include a base wall betweenportions or joining portions of the carrier. Carriers made in accordancewith the present teachings may have a wall (i.e., base wall, pluralityof projections) having a first surface and a generally opposing secondsurface. The wall may have a thickness ranging from about 0.2 to about 6mm (e.g., about 1.5 to about 4 mm).

The carrier may be made of one or more materials. The one or morematerials may be any material which allows the carrier to absorb and/ordistribute energy from an impact load; have plastic deformation due toan impact load, transfer an impact load from a first portion to a secondportion, allow the carrier to be a one-piece structure, or anycombination thereof. Suitable materials for the carrier can include forexample, and without limitation, a polymeric material such as nylon,polyamide, polysulfone, polyester, polypropylene, polyethylene, moldingcompound or the like, which may be filled or unfilled (e.g., filled withglass or kevlar reinforcement fibers); molded, extruded orotherwise-shaped metal (such as aluminum, magnesium, steel and titanium,an alloy derived from the metals, and even a metallic foam). The carriermay be formed of a thermoset or thermoplastic polymer. The carrier maycomprise a composite material, a woven material, a nonwoven material, ora combination thereof. The carrier may include at least one insert madeof a different material than the carrier. For example, if the carrier isa molded polymeric carrier, the insert may be made of a differentmaterial. The insert may have a higher yield strength than the moldedpolymeric carrier. Yield strength may be measured according to ASTM D695and/or ASTM D790. At least a portion of the carrier may include alocalized fiber reinforcement. The localized fiber reinforcement may bewoven, nonwoven, or both. The carrier may also be formed of a moldingcompound such as a sheet molding compound (SMC), a bulk molding compound(BMC), a thick molding compound (TMC) or the like. Exemplarycompositions and formation of carriers is discussed in U.S. Pat. Nos.7,313,865; 7,503,620 and U.S. Patent Application No. 2015/016737 whichare incorporated herein by reference for all purposes.

The carrier includes at least one portion. The at least one portion mayfunction to receive an impact load, absorb and/or distribute energy froman impact load, transfer an impact load to another portion, reducedeformation of another portion, include a plurality of projections,deform or collapse in stages, reside within an opening of cavity wall,or any combination thereof. The at least one portion may have any shape,size, or configuration to receive an impact load, absorb and/ordistribute energy from an impact load, transfer an impact load toanother portion, reduce deformation of another portion, include aplurality of projections, deform or collapse in stages, or anycombination thereof. The carrier may include a single portion ormultiple portions. One or more portions may be adjacent to one or moreother portions. For example, the carrier may include a first portionadjacent to a second portion. At least one portion may be located withina same cavity or an adjacent cavity as another portion. At least oneportion may receive an impact load before another portion. A portion mayabsorb at least some of the energy of the impact load beforetransferring some of the impact load to another portion. A portion mayinclude a plurality of projections to absorb at least a portion of theimpact load. At least one portion may be connected to another portion byat least one base wall. At least one portion may extend, protrude, or beadjoining another portion. One portion may have a smaller cross sectionthan another portion. A smaller portion may cooperate with a wall of acavity. A smaller portion may extend through a wall of a cavity. Forexample, when inserted into a cavity, a first portion may be insertedthrough an opening on one side of a wall and a second portion may resideon an opposing side of the wall. Insertion of a portion of a carrierthrough an opening can be found in U.S. Pat. No. 6,607,238, which isincorporated herein by reference for all purposes.

The carrier includes at least one base wall. The base wall may functionto support a plurality of projections, join one or more portions of acarrier, absorb and/or distribute energy from an impact load, transferan impact load from one portion to another portion, or any combinationthereof. The base wall may have any size and/or shape to support aplurality of projections, join one or more portions of a carrier, absorband/or distribute energy from an impact load, transfer an impact loadfrom one portion to another portion, or any combination thereof. Thewall may be generally planar or non-planar. The base wall may beintegral with at least some of the plurality of projections. The basewall may have a generally uniform thickness. The thickness of the basewall may be the same or different than the thickness of one or more ofthe plurality of projections. The base wall may have a cross-sectionalarea less than, equal to, or larger than a cross-section of all or aportion of the carrier. For example, the base wall may have across-sectional area generally equal to a cross-sectional area of aportion of the carrier, less than a cross-sectional area of a portion ofthe carrier; or both. The base wall may intersect a plurality ofprojections. For example, the base wall may intersect a plurality ofprojections which extend in opposing directions.

The structural reinforcement includes a plurality of projections. Theplurality of projections may function to receive and deform from animpact load, cooperate together to receive and deform at differenttimes, plastically deform, absorb energy from the impact load,distribute the impact load, provide reinforcement to an outwardly facingwall, provide a multi-staged deformation, or any combination thereof.The plurality of projections may have any size, shape, and/orconfiguration to receive and deform from an impact load, cooperatetogether to receive and deform at different times, plastically deform,absorb energy from the impact load, distribute the deformation, or anycombination thereof. The plurality of projections may be in the shape ofribs, posts, tabs, extensions, other protrusions from the carrier, thelike, or any combination thereof. The plurality of projections may beplanar or non-planar prior to deformation. The plurality of projectionsmay have thickness, which may be the distance from one opposing surfaceto another opposing surface. The thickness may be the distance betweentwo opposing surfaces generally orthogonal to the base wall. All or someof the plurality of projections may have a same or differing thickness.The plurality of projections may be made of materials suitable for thecarrier. One or more projections may be made of a same or differentmaterial than one or more other projections, a base wall, or otherportions of the carrier. The plurality of projections may be part of thecarrier. The plurality of projections may extend from a wall of thecarrier, such as the base wall. The plurality of projections may extendat any angle from the base wall. The plurality of projections may begenerally orthogonal to the base wall. The plurality of projections mayhave projections with differing heights (i.e., distance measured frombase wall to an opposing end of a projection). At least one projectionwith a greater height may receive an impact load and deform (i.e.,plastically deform) before at least one projection with a lesser height.Deformation of the plurality of projections may include buckling,collapsing, crushing, flexing at a hinge point (i.e., where theprojection extends from the base wall), the like, or any combinationthereof.

The plurality of projections may have a height and width. Height may bemeasured as the distance from the base wall to an opposing end of theprojection. Width may be measured as a distance from one end unattachedto the base wall to an opposing end unattached to the base wall. Theplurality of projections may have an aspect ratio of width to height.The aspect ratio may be about 1:1 or more, about 2:1 or more, about 3:1or more, or even about 4:1 or more. The aspect ratio may be about 10:1or less, about 8:1 or less, or even about 6:1 or less.

At least some of the plurality of projections may be porous. The poresmay function to allow fluid to flow through. The pores may have anyshape and/or size to allow fluid to flow through. Fluid may be definedas air, heat, e-coat fluid, the like, or any combination thereof. Thepores may also provide additional weight reduction without hinderingperformance of the reinforcement structure.

In addition, one or more openings or spaces may be provided between anyof the plurality of projections, within a wall, and/or any part of thestructural reinforcement. The one or more openings or spaces may allowfluid to flow through. The fluid may flow from outside of a vehicle tothe inside of the vehicle and/or vice-versa. The fluid may flow througha cavity into or out of a vehicle. The one or more openings or spacesmay be placed in fluid communication with a cavity of the vehicle. Theone or more openings or spaces may allow the fluid to more easily flowthrough the cavity having the structural reinforcement therein. At leasta portion of the one or more openings or spaces may remain exposed(i.e., uncovered) by a panel, vehicle surface, cavity wall, and/or thelike. The one or more openings or spaces may be located betweenprojections, within the base wall, within or adjacent to the firstportion and/or the second portion, or any combination thereof.

The plurality of projections may include at least one pair ofintersecting projections. Intersecting projections may intersectgenerally orthogonally or obliquely. Projections which intersect mayhave same or differing heights as the projections which are intersected.The plurality of projections may include generally parallel projections.The at least one pair of intersecting projections may include at leastone first projection and at least one second projection. The pluralityof projections may include projections which are aligned, staggered, oroff-set from other projections. The plurality of projections may formone or more cell-like structures. A cell-like structure may beunderstood as having at least two side surfaces formed by at least twoprojections and a base surface formed by the base wall. A cell-likestructure may be open or closed. A closed cell-like structure may beformed when four projections adjoin one another at ends extending from abase wall and form a continuous wall. An open cell-like structure may beformed when two or three projections adjoin one another at endsextending from a base wall to form a partially continuous wall.

The plurality of projections include at least one first projection. Theat least one first projection may function to receive and deform from animpact load before at least one second projection, absorb energy from animpact load before transferring a portion of the impact load, providereinforcement to an outwardly facing wall, provide a first stage ofdeformation, or any combination thereof. The at least one firstprojection may be part of a first set of projections. The first set ofprojections may include a plurality of the at least one firstprojection. The at least one first projection may be part of a first setof a plurality of projections having a similar height. The at least onefirst projection may intersect with a second projection, another firstprojection, or both. The at least one first projection may have the sameheight or a greater height than a second projection. The at least onefirst projection having a greater height may allow the first projectionto receive an impact load before a second projection. The at least onefirst projection having a greater height may allow the first projectionto begin to deform from the impact load, absorb some of the impact load,before the second projection. The at least one first projection having agreater height may allow the plurality of projections to deform in astaged manner, such that the first projection deforms before the secondprojection and defines a first stage of deformation. It may beunderstood, as opposed to having a different heights to cause initialabsorption and multi-staged deflection, the at least one firstprojection may have different material properties than the at least onesecond projection (i.e., elasticity, shock absorption, the like). The atleast one first projection and/or first set of projections may alternatewith at least one second projection and/or second set of projections.

The plurality of projections include at least one second projection. Theat least one second projection may function to receive and deform froman impact load after at least one first projection, absorb energy froman impact load before transferring a portion of the impact load, providereinforcement to an outwardly facing wall, provide a second stage ofdeformation, or any combination thereof. The at least one secondprojection may be part of a second set of projections. The second set ofprojections may include a plurality of the at least one secondprojection. The at least one second projection may be part of a secondset of a plurality of projections having a similar height. The at leastone second projection may intersect with a first projection, anothersecond projection, or both. The at least one second projection and/orsecond set of projections may be generally parallel to one another andnot intersect with another second projection. The at least one secondprojection may have the same height or a lesser height than a firstprojection. The at least one second projection having a lesser heightmay allow the second projection to receive an impact load after a firstprojection and define a second stage of deformation. The at least onesecond projection may be recessed compared to at least one firstprojection. Recessed may be defined as an exposed end of the at leastone second projection which is closer to the base wall than an exposedend of the at least one first projection. The at least one secondprojection may have a height which is at least about 25% of the heightof the at least one first projection, at least about 30% of the heightof the at least one first projection; at least about 50% of the heightof the at least one first projection; or even at least about 80% of theheight of the at least one first projection. The at least one secondprojection may have a height which is equal to the height of the firstprojection, about 95% or less than the height of the at least one firstprojection, or even about 80% or less than the height of the at leastone first projection.

The plurality of projections may form one or more walls. The one or morewalls may cooperate together to absorb and distribute the impact load,transfer at least some of the impact load to one or more other walls,absorb a certain amount of the impact load before transferring some ofthe impact load to a different portion of the carrier, or anycombination thereof. The one or more walls may be formed by at least onefirst projection, a first set of projections, at least one secondprojection, a second set of projections, or any combination thereof. Theone or more walls may form a single cell or a plurality of cells. Aplurality of projections may form a pair of sidewalls, a pair of endwalls, a bridge wall, or any combination thereof. A plurality ofprojections may form a pair of side walls. The side walls may beopposing and distanced from one another. A plurality of projections mayform a pair of end walls. The end walls may be opposing and distancedfrom one another. The end walls may be generally orthogonal or obliqueto the side walls. The pair of end walls may be adjoining the pair ofside walls. The pair of end walls and the pair of side walls may definea peripheral wall structure. The peripheral wall structure may becontinuous or discontinuous. The peripheral wall may include one or morerounded corners. The one or more rounded corners may allow thestructural reinforcement to be easily inserted through a cavity. Forexample, the rounded corners may prevent sharp corners from interferingwith one or more edges of a cavity during assembly. The one or morerounded corners may be located anywhere on the carrier, such as thefirst portion and/or second portion. The one or more rounded corners maybe formed where one or more end walls meet one or more side walls. Theplurality of projections may form at least one bridging wall. A bridgingwall may bridge a pair of side walls, a pair of end walls, or both. Thepair of side walls, pair of end walls, one or more bridging walls mayhave a same or different height as one another. The bridging wall mayhave a height less than or equal to the height of a pair of side walls,a pair of end walls, or both.

The structural reinforcement includes an activatable material. Theactivatable material may function to adhere the structural reinforcementto a surface, such as a wall of cavity. The activatable material mayfunction to provide a seal, sound mitigation, and/or structuralreinforcement. The activatable material may be located anywhere on thecarrier and be any suitable material which may adhere the structuralreinforcement to a surface; provide a seal, sound portion of a carrier.The activatable material may be located on a first portion and/or secondportion. The activatable material may surround a portion of the carrier.For example, the activatable material may be located about a section ofthe first portion of the carrier. The activatable material may becapable of activation for expansion by an external stimulus (e.g., to atleast partially fill a gap or cavity) and also may be capable of curingto form an adhesive bond to at least one surface of the article. Theresulting activated material may have application for impartingstructural rigidity or reinforcement (i.e., it may be what is regardedas a structural foam; examples of structural foam include, withoutlimitation, those available from L & L Products, Inc. under the namesL5204, L5207, L5214, L5234, L5235, L5236, L5239, L5244, L5505, L5510,L5520, L5540, L5800, L5810 and L8514.). The resulting activated materialmay have application for sealing and/or noise abatement. The resultingactivated material may be expanded to at least about 50%, 100%, 200%,400%, 600%, or even 1000% of its original volume. The resultingactivated material may be expanded from its original volume, but in anamount that is below about 2500%, 2000% or even below about 1500% of itsoriginal volume.

Suitable materials that may be employed for the activatable materialinclude expandable materials and materials that do not expand. However,it is contemplated that the activatable material can be activated toform a foam. For instance, the material may be activated to form astructural foam (e.g., the material may include an epoxy ingredient).The material may be activated to form an acoustic foam. The material maybe activated to flow for purposes of sealing a region within a cavity.The material may include a combination of a material that is activatableto expand and a material that is not activatable to expand.

The activatable material may be an epoxy based material such as thosedisclosed in U.S. Pat. Nos. 5,884,960; 6,348,513; 6,368,438; 6,811,864;7,125,461; 7,249,415; and U.S. Patent Publication Nos. 2004/0076831, and2008/0029200 hereby incorporated by reference. The activatable materialmay be a resinous generally dry to the touch or tacky and may be shapedin any form of desired pattern, placement, or thickness. The activatablematerial may be a relatively high expansion foam having a polymericformulation that includes one or more of an epoxy resin, an acetate(e.g. ethylene vinyl acetate), a thermoplastic polyether, an acrylateand/or a methacrylate (e.g., a copolymer of butyl acrylate and methylacrylate), an epoxy/elastomer adduct, and one or more fillers (e.g., aclay filler, and/or a nanoparticle-containing filler). Exemplarythermally expandable materials are disclosed in U.S. Pat. Nos.7,313,865; 7,125,461; and 7,199,165 incorporated by reference herein forall purposes. For example, and without limitation, the activatablematerial may also be an EVA/rubber based material, including an ethylenecopolymer or terpolymer that may possess an alpha-olefin. As a copolymeror terpolymer, the polymer is composed of two or three differentmonomers, i.e., small molecules with high chemical reactivity that arecapable of linking up with similar molecules. Suitable activatablematerials include those available from L&L Products, Inc. under thedesignations L7220, L2821, L1066, L205, L2010, L2105, L2108A, L2806,L2811, L4200, L4141, L4161, L4315. L5510, L5520, L5540. L5600, L5601,L7102, and L7104.

The activatable material can be formed of other materials provided thatthe material selected is heat-activated or otherwise activated by anambient condition (e.g. moisture, pressure, time or the like) and curesunder appropriate conditions for the selected application. One suchmaterial is the epoxy based resin disclosed in U.S. Pat. No. 6,131,897,the teachings of which are incorporated herein by reference. Some otherpossible materials include, but are not limited to, polyolefinmaterials, copolymers and terpolymers with at least one monomer type analpha-olefin, phenol/formaldehyde materials, phenoxy materials, andpolyurethane materials with high glass transition temperatures.Additional materials may also be used such as those disclosed in U.S.Pat. Nos. 5,766,719; 5,755,486; 5,575,526; and 5,932,680, incorporatedby reference herein for all purposes.

By way of example, the structural reinforcement may be positioned withina cavity of a transportation vehicle (e.g., an automotive vehicle) priorto coating the vehicle. The activatable material may be activated whensubjected to heat during paint shop baking operations. In applicationswhere the activatable material is a heat activated, thermally expandingmaterial, an important consideration involved with the selection andformulation of the material comprising the activatable material is thetemperature at which a material reaction or expansion, and possiblycuring, will take place. For instance, in most applications, it isundesirable for the material to be reactive at room temperature orotherwise at the ambient temperature in a production line environment.More typically, the activatable material becomes reactive at higherprocessing temperatures, such as those encountered in an automobileassembly plant, when the material is processed along with the automobilecomponents at elevated temperatures or at higher applied energy levels,e.g., during paint or e-coat curing or baking steps. While temperaturesencountered in an automobile assembly operation may be in the range ofabout 140° C. to about 220° C., (e.g., about 148.89° C. to about 204.44°C. (about 300° F. to 400° F.)), body and paint shop applications arecommonly about 93.33° C. (about 200° F.) or slightly higher. Followingactivation of the activatable material, the material will typicallycure. Thus, it may be possible that the activatable material may beheated, it may then expand, and may thereafter cure to form a resultingfoamed material.

The structural reinforcement may include one or more fasteners. The oneor more fasteners may function to affix the structural reinforcement toa surface, such as one or more walls of a cavity. The one or morefasteners may have any size, shape, or configuration to affix thestructural reinforcement to a surface. The structural reinforcement mayinclude a single fastener or a plurality of fasteners. The one or morefasteners may be integrally formed with the carrier or separately formedfrom the carrier. The structural reinforcement may include one or morefasteners that are located so that they correspond with openings formedin a wall. The structural reinforcement may include one or morefasteners that cooperate with one or more edges of a cavity. The one ormore fasteners may include a threaded fastener, an opening for receivinga fastener, a fir tree fastener, arrowhead fastener, push pin fastener,clip fastener, a hook-like fastener, a friction-fit fastener, the like,or any combination thereof. The one or more fasteners may be locatedinto and/or through an opening of a surface, such as a cavity wall, toaffix the structural reinforcement. The one or more fasteners mayreceive a surface, such as a protrusion or extension from a cavity wall,to affix the structural reinforcement.

The disclosure may relate to a method for absorbing energy in the eventof an impact to a vehicle. The method may include collapsing the carrierin a staged collapse in response to an impact load. Collapsing thecarrier may include a first portion of the carrier collapsing before asecond portion of the carrier. The first portion may collapse toward thesecond portion. The first portion may prevent or minimize collapsing ofthe second portion. During collapsing, at least one first projection mayplastically deform before at least one second projection plasticallydeforms in response to the impact load. The at least one secondprojection may receive a portion of the impact load after the at leastone first projection deforms to a certain height or other pre-determinedcondition.

While absorbing energy, the carrier may comprise a plurality ofdeformation stages to define a multi-stage deformation. The deformationstages may function to absorb part of the impact load and only transfera portion of the impact load to a subsequent stage. Each deformationstage may include deforming of at least one projection until asubsequent at least one projection begins to collapse. For example, afirst stage of deformation may be defined as deforming of at least afirst projection upon receiving the impact load before the at least onesecond projection begins to deform. For example, a second stage ofdeformation may be defined as deforming of at least a second projectionand/or continued deformation of at least one first projection uponreceiving the impact load. The number of deformation stages of a portionof the carrier may be defined by the number of different projectionswith different heights (i.e., two different projection heights result intwo deformation stages). For example, if at least one third projectionextends from the carrier, having a shorter height than the at least onesecond projection, a third deformation stage could be defined, and soforth.

The disclosure relates to a method for making the structuralreinforcement of the teachings, which is able to have a staged collapsein response to an impact load. The method may include performing finiteelement analysis to simulate the impact load. The finite elementanalysis may identify which parts of the carrier provide the moststrength, which will collapse first, what portion of a carrier mayprevent or reduce deformation of another portion of carrier, determinehow much reinforcement (number of projections) are necessary to reach acertain crash target, the like, or any combination thereof. The methodmay include generating a design of the carrier and/or reinforcementstructure based upon the results of the finite element analysis. Thedesign may include the number of projections, the location of theprojections relative to one another, the height, width, and length ofthe projections, suitable material for the carrier, the like or anycombination thereof. The method may include injection molding thecarrier according to the design. The method may include locating theactivatable material onto an external surface of the carrier. Aftermaking the structural reinforcement, it may be installed into a cavity,such as a cavity of a vehicle.

The disclosure relates to a method of installing the structuralreinforcement according to the teachings. Installing may includedisposing the structural reinforcement into the cavity or affixing thestructural reinforcement to a wall of a cavity. Installing may includeactivating the activatable material so that the activatable materialadheres to a surface of the cavity.

ILLUSTRATIVE EMBODIMENTS

The following descriptions of the Figures are provided to illustrate theteachings herein, but are not intended to limit the scope thereof.Features of any one embodiment may be employed in another.

FIG. 1 illustrates a structural reinforcement 10. The structuralreinforcement includes a carrier 11. The carrier 11 includes a firstportion 12 and a second portion 14. The carrier 11 includes activatablematerial 16 disposed thereon. The activatable material 16 is adapted toexpand outwardly to contact and adhere to one or more walls of a vehiclecavity (not shown). The structural reinforcement 10 can include one ormore channels or openings 18 (as shown in FIG. 3) which serve as apass-through for one or more automotive components (i.e., cables, wires,drain tubes). The structural reinforcement 10 can include on or morefasteners (not shown) for attaching the structural reinforcement 10 toone or more walls of a cavity. The first portion 12 is smaller than thesecond portion 14. The first portion 12 and the first portion 14 mayreside in a same cavity (not shown) or may reside in two separatecavities which are adjoined. For example, the first portion 12 may beadapted for outward placement in a first cavity (not shown) and thefirst cavity may be proximate to an outer panel of the automotivevehicle. The second portion 14 may be adapted for inward placement inthe same first cavity, or in a second cavity of the automotive vehiclewhich adjoins the first cavity and is positioned inwardly in theautomotive vehicle. The carrier 11 may include a base wall 22. The firstportion 12 may share or be joined to the second portion 14 by a basewall 22. The first portion 12 may extend from the second portion 14. Thefirst portion 12 may have a small cross-sectional area than the secondportion 14.

FIG. 2 illustrates a first portion 12 of a carrier 11. The carrier 11includes a base wall 22. Extending from the base wall 22 and oppositefrom the second portion 14 is a plurality of projections 24. Theplurality of projections include at least one first projection 23 and atleast one second projection 25. The at least one first projection 23 mayextend further from the base wall 22 as the at least one secondprojection 25. Or in other words, the at least one second projection 25may be recessed compared to the at least one first projection 23. Theplurality of projections 24 may include a first set of projections 36,including the at least one first projection 23. The first set ofprojections 36 may have a height similar to the height of the at leastone first projection 23. The plurality of projections 24 may include asecond set of projections 38, including the at least one secondprojection 25. The second set of projections 38 may have a heightsimilar to the height of the at least one second projection 25.

FIG. 2 further illustrates the plurality of projections 24 include atleast one pair of opposing and distanced side walls 26. The plurality ofprojections include at least one pair of opposing and distanced endwalls 28. The at least one pair of side walls 26 and at least one pairof end walls 28 may be adjoining one another and generally continuous. Apair of side walls 26 and a pair of end walls 28 may define one or morecell structures 30 of the carrier. A pair of side walls 26 and a pair ofend walls 28 may define a peripheral wall structure 32 of the carrier11. The plurality of projections 24 may include one or more bridgingwalls 34. The one or more bridging walls 34 are shown parallel to thepair of side walls 26 and joining one or more pairs of end walls 28.

FIG. 3 illustrates the second portion 14 of the carrier 11 from a rearside, opposite a face of the carrier 11 from which the first portion 12extends. The second portion 14 is attached to the first portion 12 via asecond plurality of projections 40 extending from the base wall 22. Thesecond plurality of projections 40 extend in an opposing direction fromthe base wall 22 as the plurality of projections 24 of the first portion12. The second plurality of projections 40 include at least one firstprojection 42. The second plurality of projections 40 may include atleast one second projection 44 (not shown). The at least one firstprojection 42 may extend further from the base wall 22 as the at leastone second projection 44 (not shown). Or in other words, the at leastone second projection 44 (not shown) may be recessed compared to the atleast one first projection 42. The second plurality of projections 40may include a first set of projections 46, including the at least onefirst projection 42. The first set of projections 46 may have a heightsimilar to the height of the at least one first projection 42. Thesecond plurality of projections 40 may include a second set ofprojections 48 (not shown), including the at least one second projection44 (not shown). The second set of projections 48 may have a heightsimilar to the height of the at least one second projection 44.

FIG. 3 further illustrates the second plurality of projections 40include at least one pair of opposing and distanced side walls 50. Theplurality of projections include at least one pair of opposing anddistanced end walls 52. The at least one pair of side walls 50 and atleast one pair of end walls 52 may be adjoining one another andgenerally continuous. A pair of side walls 50 and a pair of end walls 52may define one or more cell structures 54 of the carrier. A pair of sidewalls 50 and a pair of end walls 52 may define a peripheral wallstructure 54 of the carrier 11. The second plurality of projections 40may include one or more bridging walls 56. The one or more bridgingwalls 56 run parallel to one or more side walls 50 and connecting one ormore pairs of end walls 52.

FIGS. 4a and 4b illustrate a plan view of a first portion 12 of acarrier 11. The carrier 10 includes a first set of projections 36 and asecond set of projections 38. Some of the first set of projections 36may intersect with one another. Some of the first set of projections 36may intersect with some of the second set of projections 38. Some of thefirst set of projections 36 are parallel other projections of the firstset 36. The second set of projections 38 are parallel to one another.The second set of projections 38 may be aligned with at least some ofthe second set 38 (as shown in FIG. 4a ) and/or may be staggered oroff-set with at least projections of the second set (as shown in FIG. 4b).

FIGS. 5a and 5b illustrate cross-sectional views of a carrier 11 takenalong section A-A (exemplified in FIG. 4a ). The at least one secondprojection 25 of the first portion 12 extends from the base wall 22opposite the second portion 14. The at least one second projection 25spans the distance between opposing first projections 23. The secondportion 14 may only have a first set of projections 46 made of aplurality of first projections 42 (as shown in FIG. 5a ). The firstprojections 42 extend away from the first portion 12. The second portion14 may also have a second set of projections 48 extending from the basewall 22 opposite the first portion 12.

FIGS. 6a-6d illustrate cross-section views of the carrier 11 taken alongsection B-B (exemplified in FIG. 4b ). The first portion 12 of thecarrier 11 includes a first set of projections 36 alternating with asecond set of projections 38 (as shown in FIGS. 6a-b ). The first set ofprojections 36 and/or the second set of projections 38 may include morethan one of their respective projections before alternating to theopposing set (as shown in FIG. 6c-d ). The plurality of projections 40may even include at least one projection 37 or third set of projections39, which may have a smaller height than the second set 38. The secondportion 14 of the carrier 11 may include at least a first set ofprojections 46. The second portion 14 of the carrier may include asecond set of projections 48 (as shown in FIG. 6b-c ).

FIGS. 7-13 illustrate the structural reinforcement 10 receiving animpact load 100, such as upon impact from a vehicle collision. Theimpact load 100 is first received by the first portion 12 and isgenerally directed toward the base wall 22. The impact load 100 may bereceived by an outwardly facing wall 102 of a cavity of a vehicle body.The impact load 100 results in the at least one first projection 23and/or first set of projections 36 to begin to plastically deform (asshown in FIG. 11). As the at least one second projection 25 and/orsecond set of projections 38 are recessed compared to the at least onefirst projections and/or the first set of projections, they remain freefrom receiving the impact load at outwardly facing ends 104. The impactload 100 continuous to apply a force which then results in the at leastone first projections 23 and/or first set of projections 36 deforming toa height from the base wall 22, that the impact load is received by theoutwardly facing ends 104 of the at least one second projection 25and/or second set of projections 38. The impact load 100 plasticallydeforms the at least one second projections 25 and/or second set ofprojections 38 and continues to plastically deform the at least onefirst projection 23 and/or first set of projections 36. At apredetermined distance, deformation, or other factor, the first portion12 transfers a portion of the impact load to the second portion 14. Thesecond portion 14 may transfer the impact load to an inwardly facingwall 106 of a cavity of a vehicle body and/or may receive a counter loadfrom the inwardly facing wall 106 of the cavity. The second portion 14of the carrier 11 upon receiving the impact load 100 from the firstportion 12 may begin to plastically deform. For example, a second set ofprojections 40 may plastically deform as the structural reinforcementcontinues to absorb and distribute the impact load.

FIG. 14 illustrates a structural reinforcement 10. The structuralreinforcement includes a carrier 11. The structural reinforcement 10includes a plurality of fasteners 72 for affixing the structuralreinforcement 10 into a cavity 82 (not shown). The carrier 11 includes afirst portion 12 and a second portion 14. The first portion 12 of thecarrier 11 includes rounded corners 60. The rounded corners 60 areformed on the peripheral wall 32 where a side wall 26 is adjacent to anend wall 28. The structural reinforcement 10 includes one or moreopenings 62. The one or more openings 62 are formed in the carrier 11and can be located in the second portion 14. The one or more openings 62can also be located adjacent the first and/or second portions 12, 14.The one or more openings 62 allow for both heat and fluid to flowthrough the structural reinforcement 10 during assembly and/or operationof a vehicle or panel (not shown). Some of the one or more openings 62are formed between some of the second plurality of projections 40 of thesecond portion 14.

FIGS. 15 and 16 illustrate a structural reinforcement 10 assembled to apanel 70 of a vehicle. The structural reinforcement 10 includes aplurality of fasteners 72. The fasteners 72 include a hooked fastener74. The hooked fastener 74 is able to fit into a fastener opening 76 ofthe panel 70 and hook onto the panel 70. The fasteners 72 include twosnap-fit fasteners 78. The snap-fit fasteners 78 are able to snap ontoan edge surface 80 of a cavity 82. The panel 70 includes a cavity 82.The first portion 12 of the carrier 11 is inserted through the cavity82. The first portion 12 projects beyond an exterior surface 84 of thepanel 70. The snap-fit fasteners 78 extend from the first portion 12.The edge surface 80 may located between the snap-fit fasteners 72 andthe second portion 12 or another portion of the carrier 11. The secondportion 14 remains opposite the exterior surface 84 of the panel 70. Thefirst portion 12 has a smaller cross-sectional area than the cavity 82.The one or more openings 62 are at least partially in fluidcommunication (i.e., the openings 62 remain exposed by the panel 70)with the cavity 82 so as to allow fluid to flow through the cavity 82and the structural reinforcement 10.

As used herein, unless otherwise stated, the teachings envision that anymember of a genus (list) may be excluded from the genus; and/or anymember of a Markush grouping may be excluded from the grouping.

Unless otherwise stated, any numerical values recited herein include allvalues from the lower value to the upper value in increments of one unitprovided that there is a separation of at least 2 units between anylower value and any higher value. As an example, if it is stated thatthe amount of a component, a property, or a value of a process variablesuch as, for example, temperature, pressure, time and the like is, forexample, from 1 to 90, preferably from 20 to 80, more preferably from 30to 70, it is intended that intermediate range values such as (forexample, 15 to 85, 22 to 68, 43 to 51, 30 to 32 etc.) are within theteachings of this specification. Likewise, individual intermediatevalues are also within the present teachings. For values which are lessthan one, one unit is considered to be 0.0001, 0.001, 0.01, or 0.1 asappropriate. These are only examples of what is specifically intendedand all possible combinations of numerical values between the lowestvalue and the highest value enumerated are to be considered to beexpressly stated in this application in a similar manner. As can beseen, the teaching of amounts expressed as “parts by weight” herein alsocontemplates the same ranges expressed in terms of percent by weight.Thus, an expression in the of a range in terms of “at least ‘x’ parts byweight of the resulting composition” also contemplates a teaching ofranges of same recited amount of “x” in percent by weight of theresulting composition.”

Unless otherwise stated, all ranges include both endpoints and allnumbers between the endpoints. The use of “about” or “approximately” inconnection with a range applies to both ends of the range. Thus, “about20 to 30” is intended to cover “about 20 to about 30”, inclusive of atleast the specified endpoints.

The disclosures of all articles and references, including patentapplications and publications, are incorporated by reference for ailpurposes. The term “consisting essentially of to describe a combinationshall include the elements, ingredients, components or steps identified,and such other elements ingredients, components or steps that do notmaterially affect the basic and novel characteristics of thecombination. The use of the terms “comprising” or “including” todescribe combinations of elements, ingredients, components or stepsherein also contemplates embodiments that consist of, or consistessentially of the elements, ingredients, components or steps.

Plural elements, ingredients, components or steps can be provided by asingle integrated element, ingredient, component or step. Alternatively,a single integrated element, ingredient, component or step might bedivided into separate plural elements, ingredients, components or steps.The disclosure of “a” or “one” to describe an element, ingredient,component or step is not intended to foreclose additional elements,ingredients, components or steps.

It is understood that the above description is intended to beillustrative and not restrictive. Many embodiments as well as manyapplications besides the examples provided will be apparent to those ofskill in the art upon reading the above description. The scope of theinvention should, therefore, be determined not with reference to theabove description, but should instead be determined with reference tothe appended claims, along with the full scope of equivalents to whichsuch claims are entitled. The disclosures of all articles andreferences, including patent applications and publications, areincorporated by reference for all purposes. The omission in thefollowing claims of any aspect of subject matter that is disclosedherein is not a disclaimer of such subject matter, nor should it beregarded that the inventors did not consider such subject matter to bepart of the disclosed inventive subject matter.

1. A structural reinforcement for a vehicle comprising: a) a carrierhaving a base wall and a plurality of projections extending from thebase wall, the plurality of projections including at least one firstprojection and at least one second projection and the at least one firstprojection having a height greater than a height of the at least onesecond projection; b) an activatable material affixed to the carrier,wherein the activatable material is configured to secure the carrier ina cavity of the vehicle; wherein in event of an impact, the at least onefirst projection and the at least one second projection are configuredto deform toward the base wall, in a direction of an impact load, orboth in response to the impact load; and the at least one firstprojection is configured to receive the impact load and deform beforethe at least one second projection receives the impact load and deforms.2. The structural reinforcement of claim 1, wherein the carrier includesa first portion and a second portion separated by the base wall; and theat least one first projection and at least one second projection arepart of the first portion.
 3. The structural reinforcement of claim 2,wherein the second portion includes at least one first projectionextending from the base wall in an opposite direction as the pluralityof projections of the first portion.
 4. The structural reinforcement ofclaim 2, wherein the carrier is a molded polymeric carrier.
 5. Thestructural reinforcement of claim 4, wherein the molded polymericcarrier includes at least one insert made of a material different thanthe molded polymeric carrier; and wherein the material of the insert hasa higher yield strength than a yield strength of the molded polymericcarrier.
 6. The structural reinforcement of claim 2, wherein the carrieris a single molded one-piece structure.
 7. The structural reinforcementof claim 2, wherein at least a portion of the carrier includes localizedfiber reinforcement.
 8. The structural reinforcement of claim 2, whereinthe activatable material is activated by heat in an automotive vehiclepainting operation; and wherein the activatable material is a structuralfoam, an acoustical foam, a sealant, or a combination thereof.
 9. Thestructural reinforcement of claim 8, wherein the activatable materialexpands upon activation.
 10. The structural reinforcement of claim 2,wherein the at least one first projection is part of a first set of aplurality of projections having a similar height; and wherein the atleast one second projection is part of a second set of a plurality ofprojections having a similar height.
 11. The structural reinforcement ofclaim 10, wherein the first set of the plurality of projections and thesecond set of the plurality of projections alternate relative to eachother on the base wall.
 12. The structural reinforcement of claim 10,wherein the plurality of projections include a pair of sidewallsopposing and distanced from one another; wherein the plurality ofprojections include a pair of end walls opposing and distanced from oneanother; and wherein the pair of end walls are adjoining the pair ofsidewalls to define a peripheral wall structure which is generallycontinuous.
 13. The structural reinforcement of claim 10, wherein atleast one of the first set of the plurality of projections intersects atleast one of the second set of the plurality of projections.
 14. Thestructural reinforcement of claim 13, wherein some of the first andsecond set of the plurality of projections form one or more cell-likestructures extending from the base wall having two or more walls, threeor more walls, four or more walls, five or more walls, or anycombination thereof.
 15. The structural reinforcement of claim 10,wherein the plurality of projections include one or more ribs, posts,tabs, extensions, the like, or any combination thereof.
 16. Thestructural reinforcement of claim 2, wherein the deformation of the atleast one first projection, the at least one second projection, or bothin response to the impact load is plastic deformation.
 17. Thestructural reinforcement of claim 16, wherein the deformation of thefirst projection, the second projection, or both includes a buckling ofthe first projection, the second projection, or both.
 18. The structuralreinforcement of claim 2, wherein the carrier includes a first portionadapted for outward placement in a first cavity of the vehicle, thefirst cavity being proximate an outer panel of the vehicle; and whereinthe carrier includes a second portion adapted for inward placement in afirst cavity of the vehicle, in a second cavity of the vehicle whichadjoins the first cavity and is positioned inwardly in the vehicle, orboth.
 19. The structural reinforcement of claim 18, wherein the firstcavity of the vehicle and the second cavity of the vehicle are separatedby a wall.
 20. A method for making the structural reinforcementaccording to claim 13 comprising: a) performing finite element analysisto simulate the impact load; b) generating a design of the carrier thathas a structure according to claim 13 based upon results of the finiteelement analysis; c) injection molding the carrier according to thedesign; and d) locating the activatable material onto an externalsurface of the carrier.